Apparatus and method of loading lensfitted photo film unit with photo film

Abstract: A lens-fitted photo film unit (1) has a body (10) in which a cassette containing chamber (15) is pre-loaded with a photo film cassette. A photo film chamber contains unexposed photo film in a form of roll as drawn out of the cassette. A photo film winding wheel (6) is rotated after each exposure to rotate a spool in the cassette shell into which the photo film is wound. An apparatus for assembling the photo film unit has a dark box (30), which has three supply openings (30a-30c) into which parts are supplied, and an exit opening (30d) from which the body loaded with the photo film is exited. Four intermediate cells (34a-34d) of the dark box (30) shield ambient light, and include outer shutter plates (33a-33d) and inner shutter plates (35a-35d), which are disposed in the supply openings and the exit opening, shield ambient light, and are opened/closed in alternation. A cassette supplying loader and a robot hand (RH) transfer the cassette into the dark box (30), while a leading tongue (46a) of the photo film is protruded from the cassette shell, with a remaining portion of the photo film contained as a roll. A roll forming fork device (63) winds the photo film as much as a predetermined length from the cassette as supplied, and forms the photo film into the roll. A photo film mounting mechanism swings the roll and the cassette shell together to change orientation thereof, and loads the roll and the cassette shell into the body.

Description: The present invention relates to an apparatus and a method for automatically assembly a lens-fitted photo film unit. More particularly the present invention relates to an improvement of photo film loading apparatus and method in which loading processes are highly automated. Known lens-fitted photo film units (hereinafter referred to simply as photo film units) are disclosed in US-A-4,884,087 and US-A-4,972,649 (both corresponding to JP-B-2-32615), and are now on the market, e.g. under the trade name "Fujicolor Quick Snap" (manufactured by Fuji Photo Film Co., Ltd.). Such photo film units are a single-use camera pre-loaded with photo filmstrip (hereinafter referred to as photo film) in a cassette of a 135-type, as defined by ISO 1007, 1979 version, and incorporate a taking lens, a shutter device, and other mechanisms for photography. The photo film unit has a mechanism for winding the photo film, but lacks a mechanism of feeding the film in reverse to the winding, for the purpose of reduction in cost of production. A user who has purchased the photo film unit winds the photo film frame by frame back into the cassette after each exposure. In production of the photo film unit, a loading apparatus draws the photo film out of a cassette shell in a darkroom to give it a form of a roll, and loads a photo film chamber with the roll of the photo film, while loading a cassette containing chamber with the cassette shell. To form the roll from the drawn photo film, the loading apparatus has a station for winding the photo film. The roll forming station has a shaft device on which a leader of the photo film is secured. Although the roll is formed in the darkroom, a manual operation in an illuminated room is conventionally required before forming the roll. With the cassette shell set in the roll forming station, the manual operation pulls a predetermined length of the leader out of the cassette shell, and secures the leader of the photo film on the shaft device. The conventional operation of loading of the photo film requires much time. The length of pulling the leader from the cassette shell tends to change due to changes in the manual operation. A pulled portion on the leader is exposed to ambient light, and fogged. Accordingly a length of the photo film usable for the exposures cannot be determined as constant. An available maximum number of exposures conventionally must be as small as a standard number of which exposures could be safely taken without being fogged. GB 2 237 120 describes a disposable camera and an apparatus and method for assembling the same. The apparatus for assembling the disposable camera includes a conveyor belt travelling into, through, and out of a dark room. Along the conveyor belt, seve.ral working stations are installed. In a unit supplying station, the main body and the back cover of a disposable camera are manually put onto a base plate which also contains a film loading apparatus. The base plate having the main body, the rear cover and the film loading apparatus attached thereon is forwarded to a patron supply station for receiving the film cassette. Thereafter, the base plate enters the dark room where those operations are sequentially performed which are to be performed by shielding ambient light. Then, the base plate with the mounted camera and the film loading device leaves the dark room. Thus, the known apparatus requires to assemble all necessary parts onto a base plate before the parts enter the dark room. In view of the foregoing problems, an object of the present invention is to provide an apparatus and a method of loading a lens-fitted photo film unit with photo film, in which loading processes are highly automated. Another object of the present invention is to provide an apparatus and a method of loading a lens-fitted photo film unit with photo film, which is capable to produce the photo film unit in which an available maximum number of exposures may be raised over the standard number. The above objects are achieved by an apparatus according to claim 1 and a method according to claim 20. In the present invention, the loading processes are highly automated. It is possible to produce the photo film unit in which an available maximum number of exposures may be raised over the standard number. The above objects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments thereof when read in connection with the accompanying drawings, in which: Fig. 1 is a perspective view illustrating a lens-fitted photo film unit to be produced by a novel loading apparatus; Fig. 2 is a perspective view illustrating a main body and a rear cover of the photo film unit; Fig. 3 is an explanatory view illustrating an overall arrangement of the loading apparatus; Figs. 4A and 4B are explanatory views illustrating photo film cassettes handled while conveyed into a dark box; Figs. 5A and 5B are explanatory views illustrating a station in which a leader is pulled from the cassette; Fig. 6 is an explanatory view illustrating a station of forming the photo film into a roll and a station of loading the main body with the roll; Fig. 7 is an elevation, partially in section, illustrating a fork device in the roll forming station; Fig. 8A is a flow chart illustrating operation of transferring the main body into the dark box; Fig. 8B is a flow chart illustrating operation of transferring the photo film cassette into the dark box; Fig. 8C is a flow chart illustrating operation of transferring the rear cover into the dark box; Fig. 8D is a flow chart illustrating operation of transferring the photo film housing out of the dark box; and Fig. 9 is a flow chart illustrating operation of winding the photo film into a roll. Fig. 1 illustrates a lens-fitted photo film unit 1 to be produced in the novel assembling apparatus. A photo film housing 2 is generally formed from resin, and packaged in a cardboard wrapper 3. The housing 2 has a taking lens 4, a shutter button 5, a photo film winding wheel 6, a viewfinder 7, and an indicator 8 which shows the number of remaining frames photographable on photo film 45 (see Fig. 3). In correspondence with those outside the housing 2, the packaging 3 has openings in which they appear. The housing 2 is constituted of a main body 10, with front and rear covers 11 and 12 secured thereto. The main body 10 has an exposure frame 13, a photo film chamber 14 and a cassette containing chamber 15. The cassette containing chamber 15 has a fork 16 projected into it to be engaged with a spool of a cassette. The fork 16 is integral with the winding wheel 6. Under the photo film chamber 14 is disposed a stopper 14a formed on the main body 10. After a roll 62 of the photo film 45 (See Fig. 6) is mounted in the photo film chamber 14, the stopper 14a contacts the roll 62, resists to a force of withdrawing a fork device 63 having inserted the roll 62, and ensures removal of the roll 62 from the fork device 63. Over the exposure frame 13 is disposed a sprocket wheel 17, which comes in mesh with perforations 45a (see Fig. 5A), and is driven to rotate by movement of the photo film 45. Under the main body 10 are formed projections 18 and 19, which are used for retention between the main body 10 and the rear cover 12 after loading of the photo film 45. On the inside of the rear cover 12 is formed a rear regulating face 21, which has a curve in correspondence with the rear of the exposure frame 13 as shown, and contacts the photo film 45 to position it on the exposure frame 13. The bottom of the rear cover 12 includes holes 22 and 23 to be engaged with the projections 18 and 19, and bottom lids 24 and 25, which are retained on the main body 10 by use of retaining hooks which are omitted from the drawing. The bottom lid 24 encloses the bottom of the photo film chamber 14 in light-tight fashion. Similarly the bottom lid 25 encloses the bottom of the cassette containing chamber 15. CONSTRUCTION OF ASSEMBLING APPARATUS Fig. 3 illustrates the novel assembling apparatus. A dark box 30 is so structured that the inside is shielded from ambient light, and is provided with a supply outer opening 30a through which the main body 10 is supplied, a supply outer opening 30b through which a photo film cassette 31 is supplied, a supply outer opening 30c through which the rear cover 12 is supplied, and an exit outer opening 30d through the housing 2 is exited after loading of the photo film 45. Before supplied into the dark box 30, the main body 10 has been previously provided with a mechanism for taking photographs and the front cover 11 fitted thereon. Each of the supply outer openings 30a to 30c and the exit outer opening 30d is provided with an outer shutter plate 33a to 33d, which are disposed in slidable fashion for shielding the dark box 30 from ambient light. Behind the shutters 33a to 33d are formed respective intermediate cells 34a to 34d. Each of the intermediate cells 34a to 34d has an inner shutter plate 35a to 35d for shielding light. The inner shutter 35a is mated with the outer shutter 33a, which must be closed before the inner shutter 35a can be open, and vice versa. This structure applies to the other pairs of shutters 33b to 33d and 35b to 35d. It is possible constantly to protect the inside of the dark box 30 from ambient light, with all the four intermediate cells 34a to 34d where the inside of the dark box 30 is accessible externally. A top 36 of the dark box 30 consists of two separately openable top plates 36a and 36b. When the top plates 36a and 36b are opened, an operator of the factory where the assembling apparatus is installed can inspect the shutters 33a to 33d and 35a to 35d and other relevant devices incorporated in the dark box 30. A compartment 30e of the dark box 30 covers a turntable 40 in light-tight fashion. On the turntable 40 are mounted rear-cover holders 41 which hold each rear cover 12, and jigs 81 and 82 for receiving the main body 10 fixedly on the turntable 40 (See Fig. 6). A robot hand RH is disposed between each of the intermediate cells 34a to 34d and the turntable 40 (See Figs. 8A to 8D). The robot hands RH associated with the intermediate cells 34a to 34c are respectively operated to hold the main body 10, the cassette 31 and the rear cover 12 to place them on the turntable 40. The robot hand associated with the intermediate cell 34d is operated to pick up the housing 2 from the turntable 40, and place them into the intermediate cell 34d. Outside the supply outer opening 30b is disposed a conveyor 42, which consecutively conveys the cassette 31 in erect orientation. Near the end of the conveyor 42, an escapement 43 is disposed and separates first and second advancing cassettes from the remaining cassettes. A stopper 44 is disposed to stop the first cassette in the fixed position. The photo film 45 of the cassette 31 has a leader 46, of which a width is reduced at a leading tongue 46a. The cassette 31 conveyed on the conveyor 42 has a form such that the leading tongue 46a is protruded from out of a passageway 48a in a cassette shell 48. This protrusion of the leading tongue 46a is as far as a range of the three successive perforations 45a, as illustrated in Fig. 4A. The conveyor 42 being installed in an illuminated room, only such a small range of the leading tongue 46a is protruded and exposed to the ambient light. Therefore, it is possible to minimize the loss of the photo film 45 and utilize a definitely greater portion of the photo film 45 for photography. It is easy to handle and treat the cassette 31 in aligning and conveying the cassette 31. In Fig. 4A, a conveyance-separating loader 50 is disposed in the intermediate cell 34b. The loader 50 is extended through the supply outer opening 30b while the outer shutter 33b is opened, and simultaneously picks up the two cassettes 31 from the conveyor 42, to move them into the intermediate cell 34b. As depicted in Fig. 4A, the loader 50 while raising the two cassettes 31 enlarges the interval between them, and then places the cassettes 31 on rotary holders 51 and 52 incorporated in the intermediate cell 34b. Each of the rotary holders 51 and 52 has a vacuum chuck mechanism for sucking and retaining a bottom of each cassette 31 and a rotating mechanism for rotating the cassette 31. As illustrated in Fig. 4B, the cassettes 31 are rotated to orient the leading tongue 46a in respective predetermined directions. As illustrated in Figs. 5A and SB, each cassette 31 as oriented is set in a leader pulling station 53 disposed between the intermediate cell 34b and the turntable 40. The leader pulling station 53 consists of a cassette holder 54 for sucking and retaining the cassette shell 48, a pick-up section 55 for picking up the leading tongue 46a, an arm 56 having the pick-up section 55 fixed, and a solenoid 57 for driving the arm 56. Near to the solenoid 57, two photo sensors 58 and 59 are disposed and operate for accuracy of the appearing length of the leader 46 as pulled, e.g. to cause 15 perforations 45a to appear. The sensors 58 and 59 detect the distal edge of the leading tongue 46a. Immediately upon detection of the edge at the sensor 58, the solenoid 57 is braked. Upon detection of the same at the sensor 59, the solenoid 57 is completely stopped driving the arm 56. Note that the dark box 30 contains the two juxtaposed leader pulling stations 53, which handle each cassette 31 from the rotary holders 51 and 52, and operate simultaneously. In Fig. 6, the cassette 31 with the leader 46 pulled out is carried to, and set in, a roll forming station 60, which consists of a cassette holder 61 for sucking and retaining the cassette shell 48, a roll forming fork device 63 (See Fig. 7) for picking up the leading tongue 46a and for rotating to form the photo film 45 into the roll 62, a shifter device 64 having the cassette holder 61 as well as the fork device 63 mounted on a base plate, and a fork motor 65 incorporated under the shifter device 64 for rotating the fork device 63. Note that the fork motor 65 is linked with a rod 68 integral with the fork device 63, in disengageable fashion via gears 66 and 67. It is further to be noted that the dark box 30 contains the two juxtaposed roll forming stations 60, which handle each cassette 31 from the leader pulling stations 53, and operate simultaneously. Between the cassette holder 61 and the fork device 63, a photo sensor 69 is disposed and consists of a beam projector 69a and a beam receiver 69b for detecting a beam from the projector 69a. Existence and lack of the beam at the receiver 69b represent each passage of the one perforation 45a. Times of the beam detection are counted by a counter 70a. A controller 70 determines the amount of winding the photo film 45 while processing the count value of the counter 70a. In the course of the winding around the fork device 63, a photo film guide 71, indicated by the two-dot-chain lines, remains mounted on the fork device 63, and contacts both lateral edges of the photo film 45 to neaten the roll 62 while the photo film 45 is wound. Fig. 7 illustrates the fork device 63 in detail, which incorporates a hook 72. When the leading tongue 46a is inserted in a slot 63a, the hook 72 is engaged with one of the perforations 45a in the leading tongue 46a. The hook 72 is rotatable about a shaft 73, and has an opposite distal end 72a, which is in contact with a pressing pin 74 biased by a spring. The pressing pin 74 is contained in a recess in a screw 75, which is helically fitted through a bottom of the fork device 63. When the screw 75 is rotated by a screwdriver, the hook 72 is adjusted regarding a force of retaining the leading tongue 46a of the photo film 45. It is desirable to set the retaining force so that a force, which axially retracts the fork device 63 with the roll 62 of the photo film 45, can easily remove the fork device 63 from the roll 62 while mounted in the photo film chamber 14. The shifter device 64 is disposed as swingable through 90 degrees approximately. As illustrated in Fig. 6, orientation of the shifter device 64 is so changed, before access of the cassette shell 48 and the roll 62 to the main body 10, that a spool 77 in the cassette 31 comes in parallel with a surface defined by the turntable 40. The cassette holder 61 is slidable to project retractably. A slider 78 is associated with the fork device 63 for projection in retractable fashion. Before the cassette shell 48 and the roll 62 are mounted on the main body 10, the cassette holder 61 and the slider 78 are slid and projected at the same time. Operation of the assembling apparatus is described now. As is illustrated in the flow of Fig. 8A, the outer shutter 33a of the dark box 30 ist opened. A transfer device catches the main body 10 with the front cover 11, and brings it into the intermediate cell 34a through the supply outer opening 30a. After the outer shutter 33a is closed, the inner shutter 35a is opened. The robot hand RH places the main body 10 on the turntable 40 between the support jigs 81 and 82, and fixes it on the turntable 40. The rear cover 12, as illustrated in the flow of Fig. 8C is transferred into the intemediate cell 34c by a transfer device through the supply outer opening. After the outer shutter 33c is closed, the inner shutter 35c is opened. The robot hand RH places the rear cover 12 on the rear-cover holder 41. The cassettes 31 are conveyed by the conveyor 42. The first and second cassettes are separated from the remaining cassettes 31 by the escapement 43. The outer shutter 33b, as illustrated in Fig. 8B, is opened. The loader 50 simultaneously retains the two cassettes 31, and moves them into the intermediate cell 34b through the outer opening 30b. The two cassettes 31 are set on the rotary holders 51 and 52, before the outer shutter 33b is closed. The rotary holders 51 and 52 are rotated. Each leading tongue 46a is oriented in the predetermined directions. The inner shutter 35b is opened next. The robot hand RH sets each cassette 31 on the cassette holder 54 in the leader pulling station 53. The pick-up section 55 squeezes the leading tongue 46a, before the arm 56 is driven by the solenoid 57. The leader 46 is pulled out of the passageway 48a in the cassette shell 48. The distal end of the leading tongue 46a is detected by the sensor 58. Responsively the solenoid 57 is braked. The sensor 59 detects the leading tongue 46a. The arm 56 is stopped from driving. The leader 46 is pulled out of the cassette shell 48 as long as the predetermined length. The cassette 31 is conveyed into the roll forming station 60. The cassette shell 48 is sucked by and retained on the cassette holder 61. The leading tongue 46a is inserted in the slot 63a in the fork device 63. Then the fork device 63 is rotated, and winds the photo film 45. The guide 71 neatly forms end faces of the roll 62 of the photo film 45. The perforations 45a detected by the sensor 69 are counted by the counter 70a, of which the count value is checked by CPU 70. CPU 70 according to the count value determines how many perforations are in the cassette shell 48. As soon as there remain a small number of perforations, for example from zero to three, or from zero to four, then the fork device 63 is stopped. The guide 71 is removed from the fork device 63. The cassette holder 61 and the slider 78 are slid and extended. The spool 77 is oriented to be parallel with the turntable 40. The shifter device 64 inclines through 30 degrees so that the roll 62 is raised over the cassette shell 48. The cassette shell 48 is mounted on the cassette containing chamber 15. An advancing end of the spool 77 is engaged with the fork 16. Then the shifter device 64 swings down about the spool 77 through 30 degrees. The roll 62 is mounted into the photo film chamber 14. The rear cover 12, supplied as in Fig. 8C, is fitted on the main body 10, and pressed against it. The retaining projections 18 and 19 are fitted in the openings 22 and 23, to retain the rear cover 12 on the main body 10. The cassette shell 48 is released from the suction of the cassette holder 61. The cassette holder 61 and the slider 78 are shortened while slid. The bottom face of the roll 62 is contacted on the stopper 14a. The fork device 63 is withdrawn from the roll 62, though the roll 62 is kept in the photo film chamber 14. The bottom lids 24 and 25 are closed, to obtain the housing 2 which is loaded with the photo film 45. The turntable 40 is rotated. The housing 2 is brought to confront the intermediate cell 34d. As is illustrated in Fig. 8D, the inner shutter 35d is opened. The robot hand transfers the housing 2 into the intermediate cell 34d. Then the inner shutter 35d is closed, before the outer shutter 33d is opened. The housing 2 is exited from the intermediate cell 34d and from the dark box 30. The housing 2 is conveyed by a conveyor belt to a following process in which the housing 2 is covered by the cardboard wrapper 3. Note that, in the above embodiment, the two rolls 62 of the photo films 45 are formed simultaneously. The two cassettes 31 are inserted into each main body 10 simultaneously. This is preferable in view of efficiency in loading. However the present invention is applicable to an assembling apparatus in which the single roll 62 of the photo film 45 is formed at one time, and the single cassette 31 inserted into the main body 10 at one time. In the above, the winding amount of the photo film 45 is measured by counting the number of perforations 45a as passed. Alternatively, the winding amount of the photo film 45 may be measured by use of a rotary encoder associated with the fork motor 65. The winding amount can be represented by the number of pulses of rotation of the fork motor 65. Otherwise, the winding amount may be measured by combination of a rotary encoder and nip rollers, which may be arranged in a path of the photo film, and whose amount of rotation can be read by the rotary encoder. Alternatively, the winding amount may be measured by use of an impeller associated with the fork motor. The winding amount can be represented by the number of pulses of the impeller. In the above embodiment, the main body 10 is laid on the turntable. The cassette 31 with the photo film 45 are erect on the shifter device 64, and swung down before loading into the main body 10. Alternatively the main body 10 may be erected on the turntable. The cassette 31 with the photo film 45 can be kept erect during loading into the main body 10. In the above, the assembling apparatus is adapted to loading the lens-fitted photo film unit with the photo film 45. However the present invention is applicable to any system for loading of photosensitive material. In the above embodiment, the turntable 40 is used for consecutively conveying the main body 10. The dark box 30 has a rectangular shape. Alternatively a conveyor mechanism of an endless type may be used to convey the main body 10 along an orbital path. A dark box with this can be shaped like a doughnut. Although the present invention has been fully described by way of the preferred embodiments thereof with reference to the accompanying drawings, various changes and modifications will be apparent to those having skill in this field. Therefore, unless otherwise these changes and modifications depart from the scope of the present invention, they should be construed as included therein.

Claims: An apparatus for automatically assembling a lens-fitted photo film unit comprising a main body (10) having a cassette containing chamber (15) pre-loaded with a photo film cassette (31) and a photo film chamber (14) for containing unexposed photo film in the form of a roll drawn out of said photo film cassette, wherein a photo film winding wheel is rotated after each exposure to rotate a spool in said cassette into which said photo film is wound, said assembling apparatus comprising: a dark box (30) comprising a light-shielded compartment (30e) and having a plurality of supply openings (30a,30b,30c) into which parts are supplied, an exit opening (30d) from which said body loaded with said photo film is exited, and a plurality of intermediate cells (34a-34d) located between the periphery of said dark box (30) and said light-shielded compartment (30e) for shielding ambient light, said intermediate cells including outer openings provided with outer shutter plates (33a-33d) and inner openings provided with inner shutter plates (35a-35d), said outer and inner openings forming said supply openings and said exit opening, said outer shutter plates and said inner shutter plates shielding ambient light and being opened/closed in alternation; photo film cassette supplying means (50,RH) for transferring said photo film cassette into said dark box, while a small portion of a leader (46) of said photo film is protruded from said cassette, with a remaining portion of said photo film contained in said cassette as a roll; roll forming means (63), disposed in said dark box, for winding said photo film as much as a predetermined length from said photo film cassette as supplied, and for forming said photo film into a roll which is to be positioned in said photo film chamber; and photo film mounting means (61,63,64), disposed in said dark box, for swinging said roll and said cassette together relatively to said main body (10) to change orientation thereof, and for mounting said roll into said photo film chamber and said cassette into said cassette containing chamber. An assembling apparatus according to claim 1, wherein the dark box (30) has one light-shielded compartment (30e) first to Nth intermediate cells (34a-34d) formed individually on said periphery of said compartment (30e); first to Nth outer openings (30a-30d) formed in an outer wall of said dark box; first to Nth outer shutter plates (33a-33d); first to Nth inner openings formed in respective walls between said compartment and a respective one of said first to Nth intermediate cells; and first to Nth inner shutter plates (35a-35d); first transfer means associated with said first intermediate cell (34a) for transferring said main body into said first intermediate cell through said first outer opening (30a) while said first outer shutter plate (33a) is open, said first transfer means further transferring said main body into said compartment from said first intermediate cell while said first inner shutter plate (35a) is open after said first outer shutter plate is closed; a consecutive conveyor device (40) positioned in said dark box and shielded from ambient light for periodical movement in order to pass said main body entered in said compartment from a position at said first intermediate cell sequentially through positions at said second to Nth intermediate cells; second transfer means (50,RH), forming said photo film cassette supply means, associated with said second intermediate cell (34b) for transferring said photo film cassette, said photo film cassette being moved into said second intermediate cell through said second outer opening (30b) while said second outer shutter plate (33b) is open, said second transfer means further transferring said photo film cassette into said compartment from said second intermediate cell while said second inner shutter plate (35b) is open after said second outer shutter plate is closed; said mounting means (61,63,64) being disposed in said compartment, for mounting said photo film cassette, supplied from said second intermediate cell, into said cassette containing chamber in said main body, and for mounting said photo film drawn out of said photo film cassette into said photo film chamber in said main body; and wherein exiting means are associated with said Nth intermediate cell (34d) for moving said main body with said photo film cassette and said photo film mounted, said main body being transferred into said Nth intermediate cell through said Nth inner opening while said Nth inner shutter plate (35d) is open, said exiting means further transferring said main body from said Nth intermediate cell through said Nth outer opening (30d) while said Nth outer shutter plate (33d) is open after said Nth inner shutter plate is closed. An assembling apparatus as defined in claim 2, wherein said mounting means (61,65,63) comprises: a cassette holding device (61) for holding said photo film cassette supplied from said second intermediate cell while a leader (46) of said photo film is protruded; and a rotary shaft device (63) on which said leader is mounted while said cassette holding device holds said photo film cassette, said rotary shaft device being rotated to wind said photo film (45) thereabout. An assembling apparatus as defined in claim 3, further comprising: an auxiliary cassette holding device (54) disposed in said compartment for holding said photo film cassette (31), said photo film cassette being set on said auxiliary cassette holding device by said second transfer means (50,RH); and a pulling device (55,56,57) disposed beside said auxiliary cassette holding device for pulling said leader (46) out of said photo film cassette. An assembling apparatus as defined in any one of claims 1 to 4, wherein: said main body further includes an exposure frame formed between said cassette containing chamber and said photo film chamber for effecting exposure on said photo film; and said photo film cassette further includes a cassette shell having a photo film passageway, and a spool disposed in said photo film chamber rotatably for winding said photo film thereabout, wherein an exposed portion of said photo film is wound back into said photo film cassette after effecting said exposure. An assembling apparatus as defined in any one of claims 1 to 5, wherein said main body includes a winding wheel mounted over said cassette containing chamber and connected to said spool in said cassette in said cassette containing chamber. An assembling apparatus as defined in any one of claims 2 to 6, wherein said consecutive conveyor device (40) moves rotationally, and said first to Nth intermediate cells (34a-34d) are arranged around said compartment. An assembling apparatus as defined in any one of claims 2 to 7, wherein said N is at least 4, and said lens-fitted photo film unit further includes a rear cover (12) secured behind said main body and a front cover secured in front of said main body; and wherein said apparatus further comprises third transfer means associated with said third intermediate cell (34c) for transferring said rear cover, said rear cover being transferred into said third intermediate cell through said third outer opening (30c) while said third outer shutter plate (33c) is open, said third transfer means further transferring said rear cover into said compartment from said third intermediate cell while said third inner shutter plate (35c) is open after said third outer shutter plate is closed. An assembling apparatus as defined in claim 8, further comprising: a conveyor device (42) for conveying said photo film cassettes (31) aligned in a row; an escape device (43) for separating first two of said aligned photo film cassettes conveyed on said conveyor device from the remaining aligned photo film cassettes, said first two photo film cassettes being retained and transferred into said second intermediate cell (34b) by said second transfer means (50,RH); and two rotary holders disposed in said second intermediate cell and supplied with said first two photo film cassettes respectively, for rotating after said second outer shutter plate (33b) is closed, said rotary holders adjusting the orientation of said leader (46) of said first two photo film cassettes. An assembling apparatus as defined in claim 4, which further comprises an auxiliary carrying device for carrying said photo film cassette (31), with said leader (46) drawn out, to said mounting means; and wherein said pulling device (55,56,57) includes: a pick-up member (55) for picking up said leader; an arm (56) on which said pick-up member is mounted; and a solenoid (57) for driving said arm away from said photo film cassette to cause said pick-up member to move said leader. An assembling apparatus as defined in claim 10, further comprising: a sensor (58,59), disposed in a path of said leader (46) while pulled from said photo film cassette (31), for detecting passage of a distal end (46a) of said leader; and control means (70) for stopping said solenoid (57) in response to detection of said distal end, said leader being pulled as long as a predetermined length. An assembling apparatus as defined in claim 3, further comprising: a sensor (69), disposed between said cassette holding device (61) and said rotary shaft device (63), for detecting perforations (45a) in said photo film (45); a counter (70a), supplied with an output of said sensor, for counting said perforations in said photo film to detect a moving amount of said photo film; and control means (70) for stopping rotation of said rotary shaft device when said photo film within said photo film cassette has a length as small as a predetermined amount. An assembling apparatus as defined in claim 12, further comprising a guide member (71), mounted on said rotary shaft device (63), and contacted on lateral edges of said photo film (45), for neatening turns of said photo film, said guide member being removed from said rotary shaft device after said rotary shaft device is stopped from rotating. An assembling apparatus as defined in claim 3, wherein said mounting means (61,63,64) further includes a movable shifter device (64) on which said cassette holding device (61) and said rotary shaft device (63) are mounted, and which shifts said cassette holding device and said rotary shaft device together toward said main body, to mount said photo film cassette and said photo film into said cassette containing chamber (15) and said photo film chamber (14) in said main body. An assembling apparatus as defined in claim 14, wherein said shifter device (64) includes a base plate on which said cassette holding device (61) and said rotary shaft device (63) are erected; said main body (10) is laid on said consecutive conveyor device (40); and said shifter device moves to lay said cassette holding device and said rotary shaft device. An assembling apparatus as defined in claim 15, further comprising: a holder sliding device mounted on said shifter device (64) for sliding said cassette holding device (63) in projection from said shifter device; and a shaft sliding device (78) mounted on said shifter device for sliding said rotary shaft device (63) in projection from said shifter device; wherein said cassette holding device and said rotary shaft device after being slid, are shifted by said shifter device. An assembling apparatus as defined in claim 16, wherein said shifter device (64) shifts said cassette holding device (61) toward said cassette containing chamber (15), mounts said photo film cassette (31) in said cassette containing chamber, subsequently shifts said rotary shaft device (63) into said photo film chamber (14), and mounts said photo film (45) in said photo film chamber. An assembling apparatus as defined in claim 17, wherein: said rear cover (12) is secured to said main body (10) with said photo film cassette (31) and said photo film (45) having been mounted; and subsequently said holder sliding device and said shaft sliding device (78) slides in retraction, to retract said cassette holding device (61) and said rotary shaft device (63). An assembling apparatus as defined in claim 18, wherein said main body (10) includes a U-shaped stopper portion (14a) formed under said photo film chamber (14), said rotary shaft device (63) is retracted axially through a central cutout defined by said stopper portion, and said roll of said photo film (45) remains in said main body. A method of automatically assembling a lens-fitted photo film unit comprising a main body (10) having a cassette containing chamber (15) pre-loaded with a photo film cassette (31) and a photo film chamber (14) for containing unexposed photo film (45) in the form of a roll drawn out of said photo film cassette, said assembling method comprising the steps of: forming in a dark box (30) a light-shielded compartment and first to Nth intermediate cells (34a-34d) individually on a periphery of said compartment; forming first to Nth outer openings (30a-30d) in an outer wall of said dark box and in correspondence with respective said first to Nth intermediate cells; disposing first to Nth outer shutter plates (33a-33d) in respective said first to Nth outer openings in openable fashion; forming first to Nth inner openings in respective walls between said compartment and respective said first to Nth intermediate cells; disposing first to Nth inner shutter plates (35a-35d) in respective said first to Nth inner openings in openable fashion; transferring said main body into a first of said intermediate cells (34a) through a first outer opening (30a) while a first outer shutter plate (33a) is open; transferring said main body into said compartment from said first intermediate cell while said first inner shutter plate (35a) is open after said first outer shutter plate is closed; setting said main body on a consecutive conveyor device (40) positioned in said compartment of said dark box and shielded from ambient light; driving said consecutive conveyor device periodically, to pass said main body from a position at said first intermediate cell sequentially through positions at a second to Nth intermediate cells; transferring said photo film cassette into said second intermediate cell (34b) through a second outer opening (30b) while a second outer shutter plate (33b) is open; transferring said photo film cassette into said compartment from said second intermediate cell while a second inner shutter plate (35b) is open after said second outer shutter plate is closed; mounting said photo film cassette into said cassette containing chamber in said main body; mounting said photo film drawn out of said photo film cassette into said photo film chamber in said main body; transferring said main body, with said photo film cassette and said photo film mounted, into said Nth intermediate cell (34d) through said Nth inner opening while said Nth inner shutter plate (35d) is open; and transferring said main body from said Nth intermediate cell through said Nth outer opening (30d) while said Nth outer shutter plate (33d) is open after said Nth inner shutter plate is closed. An assembling method as defined in claim 20, wherein said N is at least 4, and said lens-fitted photo film unit further includes a rear cover (12) secured behind said main body and a front cover secured in front of said main body; and which further comprises the steps of: transferring said rear cover into a third intermediate cell (34c) through a third outer opening (30c) while a third outer shutter plate (33c) is open; and transferring said rear cover into said compartment from said third intermediate cell while a third inner shutter plate (35c) is open after said third outer shutter plate is closed. An assembling method as defined in claim 20 or 21, further comprising the steps of: conveying a plurality of said photo film cassettes (31) aligned in a row; separating a first and a second one of said aligned photo film cassettes conveyed on said conveyor device from the row of aligned photo film cassettes; retaining said first two photo film cassettes; transferring said first two photo film cassettes into said second intermediate cell (34b) through said second outer opening (30b); and in said second intermediate cell, rotating said first two photo film cassettes after said second outer shutter plate (33b) is closed, to adjust orientation of said leader (46) of said first two photo film cassettes. An assembling method as defined in any one of claims 20 to 22, wherein said mounting step comprises: holding said photo film cassette supplied from said second intermediate cell while a leader (46) of said photo film is protruded; securing said leader on a rotary shaft device (63) while said cassette holding device holds said photo film cassette; and rotating said rotary shaft device to wind said photo film (45) thereabout. An assembling method as defined in claim 23, further comprising steps of: holding said photo film cassette (31) in said compartment; and pulling said leader (46) out of said photo film cassette. An assembling method as defined in claim 23 or 24, further comprising the steps of: detecting perforations (45a) in said photo film (45) between said photo film cassette (31) and said rotary shaft device (63); counting said detected perforations to detect a moving amount of said photo film; and stopping rotation of said rotary shaft device when said moving amount becomes as great as a predetermined amount. An assembling method as defined in claim 25, further comprising a step of mounting a guide member (71) on said rotary shaft device (63) and in contact with lateral edges of said photo film (45), to neaten turns of said photo film. An assembling method as defined in any one of claims 23 to 26, further comprising the steps of: in said winding step, erecting said photo film cassette (31) and said rotary shaft device (63); and laying said photo film cassette and said rotary shaft device, which are shifted toward said main body. An assembling method as defined in claim 27, wherein said photo film (45) is mounted in said photo film chamber (14) after said photo film cassette (31) is mounted in said cassette containing chamber (15). An assembling method as defined in claim 20, comprising the steps of: pulling a leader (46) of said photo film out of said photo film cassette supplied from said second intermediate cell; securing said leader on a rotary shaft device (63) while said photo film cassette is held; rotating said rotary shaft device to wind said photo film thereabout; and shifting said photo film cassette and said rotary shaft device together toward said main body.

Inventors: SUZUKI CHIAKI, TSUNEKAWA YUZO, SUZUKI, CHIAKI, TSUNEKAWA, YUZO, Suzuki, Chiaki, c/o Fuji Photo Film, Co., Ltd., Tsunekawa, Yuzo, c/o Fuji Photo Film, Co., Ltd.
Applicants: FUJI PHOTO FILM CO LTD, FUJI PHOTO FILM CO., LTD.
Application year: 1994
Main classification: G03B17
IPC codes: G03B19, G03B17, G03C3